In-line lamination method and apparatus

ABSTRACT

A lamination system includes a film supply, a material supply, and a laminator. The laminator causes a film from the film supply to be laminated to a sheet from the material supply to establish a laminated sheet.

PRIORITY CLAIM

This application is a continuation of U.S. patent application Ser. No.15/493,240, filed Apr. 21, 2017, which claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 62/326,374, filed Apr. 22,2016, each of which is expressly incorporated by reference herein.

BACKGROUND

The present disclosure relates to a lamination system, and particularlyto a system for laminating a web to a film.

SUMMARY

According to the present disclosure, a lamination system includes a filmsupply, a material supply, and a laminator. The laminator causes a filmfrom the film supply to be laminated to a web from the material supplyto establish a laminated sheet.

In illustrative embodiments, the lamination system further includes aslitter. The slitter slits the film to establish strips of film whichpass through the laminator for bonding with the web from the materialsupply. The material supply includes a first web and a second web.

In illustrative embodiments, the laminator includes a pair of laminationnip rollers and adhesive applicators. The adhesive applicators areconfigured to selectively apply adhesive to portions of the first andsecond webs. The first web passes through the lamination nip rollersalong a first side of the film strips and the second web passes throughthe lamination nip rollers along a second side of the film stripsopposite the first side. The first web is bonded to some of the filmstrips and the second web is bonded to the remaining film strips to formlaminate sheets having alternating zones of film and material.

In illustrative embodiments, the laminator includes two laminationstations. Each lamination station includes adhesive applicators andlamination nip rollers. The first web and some of the film strips passthrough a first lamination station to form a first laminate sheet. Thesecond web and the other film strips pass through a second laminationstation to form a second laminate sheet.

In illustrative embodiments, the laminator includes alignment niprollers and an ultrasonic welder. Kiss coaters apply an anti-bondmaterial to portions of the first and second webs. The ultrasonic welderbonds the film strips to the uncoated portions of the webs to formseparate laminate sheets.

In illustrative embodiments, the laminator includes two laminationstations. Each lamination station includes alignment nip rollers and anultrasonic welder. The first web and some of the film strips passthrough a first lamination station to form a first laminate sheet. Thesecond web and the other film strips pass through a second laminationstation to form a second laminate sheet.

Additional features of the present disclosure will become apparent tothose skilled in the art upon consideration of illustrative embodimentsexemplifying the best mode of carrying out the disclosure as presentlyperceived.

BRIEF DESCRIPTIONS OF THE DRAWINGS

The detailed description particularly refers to the accompanying figuresin which:

FIG. 1 is an upper perspective view of an in-line lamination system inaccordance with the present disclosure showing that a film is slit intostrips and fed through a pair of lamination nip rollers to bond withnon-woven webs feeding through the same pair of lamination nip rollersand suggesting that some of the strips of film adhere to an uppernon-woven web while the other strips of film adhere to a lower non-wovenweb such that laminate sheets are formed having alternating zones ofnon-woven material and film along their widths as the laminate sheetsare vertically separated from one another;

FIG. 2 is a side elevation view of the in-line lamination system of FIG.1 showing that a single sheet of film is combined with two sheets ofnon-woven material to form two sheets of laminated material for use insubsequent processing;

FIG. 3 is a front elevation view of the in-line lamination system ofFIG. 1 showing the diverging laminate sheets after leaving thelamination nip rollers and suggesting that a width of the uppernon-woven web (W₂) is larger than a combined width of the incomingstrips of film (W₁) which is larger than a width of the lower non-wovenweb (W₃) where an odd number of strips of film are used to form thelaminate sheets;

FIG. 4 is a front elevation view of another embodiment of an in-linelamination system in accordance with the present disclosure showingdiverging laminate sheets of film and non-woven material after leavinglamination nip rollers of the in-line lamination system and suggestingthat a width of an upper non-woven web (W₂) is equal to a width of theincoming film (W₁) which is equal to a width of the lower non-woven web(W₃) where an even number of strips of film are used to form thelaminate sheets;

FIG. 5 is an upper perspective view of another embodiment of an in-linelamination system in accordance with the present disclosure showing thatthe in-line lamination system includes two lamination stations andsuggesting that a single film is slit into multiple strips with somestrips passing through an upper lamination station to bond with anon-woven web and form a first laminate sheet and the other strips offilm passing through a lower lamination station to bond with a non-wovenweb and form a second laminate sheet;

FIG. 6 is a side elevation view of the in-line lamination system of FIG.5;

FIG. 7 is a side elevation view of another embodiment of an in-linelamination system in accordance with the present disclosure showing thatthe in-line lamination system includes adhesive applicators configuredto dispense adhesive on strips of film as the strips enter upper andlower pairs of lamination nip rollers to adhere with non-woven webs toform laminate sheets;

FIG. 8 is a side elevation view of another embodiment of an in-linelamination system in accordance with the present disclosure showing afilm, an upper non-woven web, and a lower non-woven web are aligned withone another to move toward lamination nip rollers for laminating;

FIG. 9 is a side elevation view of another embodiment of an in-linelamination system in accordance with the present disclosure showing thatthe in-line lamination system includes a pair of alignment nip rollersconfigured to gather and align strips of film with upper and lowernon-woven webs and an ultrasonic welder for bonding the strips of filmwith the non-woven webs to form separate laminate sheets and suggestingthat kiss coaters apply an anti-bond material to the non-woven webs toallow zoned bonding of the non-woven webs with the film strips;

FIG. 10 is an upper plan view of the kiss coater of FIG. 9 showing thatthe kiss coater includes a kiss roller and one or more pass-over skidsand suggesting that the kiss roller gathers anti-bond material forapplication on the non-woven web as the non-woven web passes over thekiss roller and that the skids block application of the anti-bondmaterial to portions of the non-woven web;

FIG. 11 is a side elevation view of another embodiment of an in-linelamination system in accordance with the present disclosure showing thatthe in-line lamination system includes two pairs of alignment niprollers configured to gather and align strips of film with upper andlower non-woven webs and ultrasonic welders for bonding the strips offilm with the non-woven webs to form separate laminate sheets;

FIG. 12 is a diagrammatic view of the in-line lamination system of FIG.1 showing that the in-line lamination system includes a film supply, anoptional breathable film activation station, an optional elastic filmactivation station, an optional printer for printing on the film, a filmslitter, and a laminator;

FIG. 13 is a view similar to FIG. 12 showing one embodiment ofsubsequent processing stations in the in-line lamination systemincluding an optional laminate sheet slitter and laminate sheet roll-upstation;

FIG. 14 is a view similar to FIG. 13 showing another embodiment ofsubsequent processing stations in the in-line lamination systemincluding a laminate sheet alignment station, a sheet lamination stationfor forming multiple sections of laminate product, an optional laminateproduct slitter to separate adjacent sections of laminate product intostrips, and a laminate product roll-up station;

FIG. 15 is a sectional view of one laminate product formed by thein-line lamination system of FIG. 14 showing that the laminate productincludes two outer layers of non-woven material with two narrower innerlayers of film;

FIG. 16 is a side elevation view of another embodiment of an in-linelamination system in accordance with the present disclosure showing thatthe in-line lamination system includes a pair of lamination nip rollersconfigured to bond strips of film with non-woven webs feeding throughthe same pair of lamination nip rollers and suggesting that kiss coatersapply an anti-bond material to the non-woven webs to allow zoned bondingof the non-woven webs with the film strips; and

FIG. 17 is a side elevation view of another embodiment of an in-linelamination system in accordance with the present disclosure showing thatthe in-line lamination system includes a pair of lamination nip rollersto bond strips of film with non-woven webs feeding through the same pairof lamination nip rollers and suggesting that print heads apply ananti-bond material to the film to allow zoned bonding of the non-wovenwebs with the film strips.

DETAILED DESCRIPTION

An in-line lamination system 10 in accordance with the presentdisclosure is shown in FIG. 1. In-line lamination system 10 includes afilm slitter 12 and a laminator 14. A film 16, such as a breathable orelastic plastic film, is delivered from a film supply, such as anextruder 62 shown in FIG. 12, and passes through slitter 12 to dividefilm 16 into strips 18. Strips 18 pass through laminator 14 to bond withnon-woven webs 13, 15 to form separate laminate sheets 17, 19 (sometimescalled a bi-laminate) having alternating sections of exposed non-wovenmaterial 34 and film 36 laminated to and covering a portion of theunderlying non-woven material as suggested in FIGS. 3 and 4. Eachlaminate sheet 17, 19 is configured to be separated into multiple stripsof laminate material having a central section of film 36 and sections ofnon-woven material 34 extending along side edges of film section 36. Insome embodiments, film 16 is pre-processed before lamination assuggested in FIG. 12. In some embodiments, laminate sheets 17, 19 arepost-processed after lamination as suggested in FIGS. 13-15.

In the illustrative embodiment, laminator 14 includes adhesiveapplicators 22 and lamination nip rollers 24 as shown in FIGS. 1 and 2.A non-woven material supply 26 includes supply rolls 23, 25 for feedingnon-woven webs 13, 15 into lamination nip rollers 24 as suggested inFIG. 2. Non-woven webs or fabrics may be formed from many processes,such as, for example, meltblowing processes, spunbonding processes,hydroentangling processes, and bonded carded web processes. Film strips18 pass through lamination nip rollers 24 such that non-woven web 13extends along an upper side of film strips 18 and non-woven web 15extends along a lower side of film strips 18.

Adhesive applicators 22 are arranged to apply an adhesive material alongportions of non-woven webs 13, 15 where film strips 18 are to be bondedas suggested in FIG. 1. In the illustrative embodiment, adhesiveapplicators 22 apply adhesive onto lower non-woven web 15 along twospaced apart lanes such that two film strips 18 b, 18 d bond with lowernon-woven web 15. Similarly, adhesive applicators 22 apply adhesive ontoupper non-woven web 13 along three spaced apart lanes such that theremaining three film strips 18 a, 18 c, 18 e bond with upper non-wovenweb 13.

Lamination nip rollers 24 apply pressure to film strips 18 and non-wovenwebs 13, 15 to bond film strips 18 with the respective non-woven webs13, 15 and form laminate sheets 17, 19 as suggested in FIGS. 1 and 2. Insome embodiments, lamination nip rollers 24 are heated or cooled.Divider rollers 28 separate laminate sheets 17, 19 as suggested in FIG.2. Adjacent film strips 18 a, 18 b, 18 c, 18 d, 18 e diverge and arecarried on non-woven webs 13, 15 as laminate sheets 17, 19 separate fromone another as suggested in FIG. 1. Film strips 18 a, 18 c, 18 e formpart of laminate sheet 17 while film strips 18 b, 18 d form part oflaminate sheet 19. The distance between film slitter 12 and laminator 14is minimized to minimize the distance traveled by film strips 18, whichmay be susceptible to tearing, before being bonded with non-woven webs13, 15. Likewise, film strips 18 move in the machine direction ofin-line lamination system 10 and do not experience lateral changes indirection to minimize stress on film strips 18 before lamination withnon-woven webs 13, 15.

Film strips 18 bonded to each laminate sheet 17, 19 are spaced apartfrom one another as suggested in FIG. 3. In a post-processing step,non-woven material 34 positioned between adjacent film strips 18 oflaminate sheets 17, 19 is cut along slit lines 39 (shown in phantom) toseparate laminate sheets 17, 19 into multiple strips of laminatematerial 32. Each strip of laminate material 32 includes sections ofnon-woven material 34 positioned along opposing edges of a section offilm 36. A width of non-woven material sections 34 compared to a widthof film section 36 can be varied at the selection of an operator ofin-line lamination system 10. In some embodiments, non-woven materialsections 34 are each half as wide as film section 36. In someembodiments, non-woven material sections 34 are each less than half aswide as film section 36. In some embodiments, portions of non-wovenmaterial sections 34 are trimmed away such that non-woven materialsections 34 are each less than half as wide as film section 36.

In one illustrative embodiment, a width W₂ of upper non-woven web 13 islarger than a combined width W₁ of the incoming film strips 18, andwidth W₁ is larger than a width W₃ of lower non-woven web 15 where anodd number of film strips 18 are used to form laminate sheets 17, 19 assuggested in FIG. 3. Center lines of non-woven webs 13, 15 and film 16are aligned during lamination through laminator 14 as shown in FIG. 3.In another illustrative embodiment, widths W₁, W₂, W₃ are equal to oneanother when an even number of film strips 18 are used to form laminatesheets 17, 19 as suggested in FIG. 4. Center lines of non-woven webs 13,15 and film 16 are misaligned during lamination through laminator 14 asshown in FIG. 4. The relative sizes of film 16 and non-woven webs 13, 15are adjustable at the selection of an operator of in-line laminationsystem 10.

Another embodiment of an in-line lamination system 210 in accordancewith the present disclosure is shown in FIGS. 5 and 6. In-linelamination system 210 is similar to in-line lamination system 10 andincludes a film slitter 212 and a laminator 214. A film 216, such as abreathable or elastic plastic film, passes through slitter 212 to dividefilm 216 into strips 218. Strips 218 pass through laminator 214 to bondwith non-woven webs 213, 215 to form separate laminate sheets 217, 219having alternating sections of exposed non-woven material and filmlaminated to and covering a portion of the underlying non-wovenmaterial.

In the illustrative embodiment, laminator 214 includes two laminationstations 242, 244 as shown in FIGS. 5 and 6. Each lamination station242, 244 include adhesive applicators 222 and lamination nip rollers224. A non-woven material supply 226 includes supply rolls 223, 225 forfeeding non-woven webs 213, 215 into lamination stations 242, 244,respectively. Adjacent film strips 218 are directed to one of laminationstations 242, 244 in an alternating pattern such that film strips 218 a,218 c, 218 e pass through lamination station 242 to bond with non-wovenweb 213 while the remaining film strips 218 b, 218 d pass throughlamination station 242 to bond with non-woven web 215 as suggested inFIG. 5. An idler 246 guide's film strips 218 toward lamination station244.

Adhesive applicators 222 are arranged to apply an adhesive materialalong portions of non-woven webs 213, 215 where film strips 218 are tobe bonded as suggested in FIG. 5. In the illustrative embodiment, filmstrips 218 a, 218 c, 218 e passing through lamination station 242 arelaterally spaced apart from one another and adhesive applicators 222apply adhesive onto upper non-woven web 213 along spaced apart laneswhere film strips 218 a, 218 c, 218 e are to be bonded with uppernon-woven web 213. Similarly, film strips 218 b, 218 d passing throughlamination station 244 are laterally spaced apart from one another andadhesive applicators 222 apply adhesive onto lower non-woven web 215along spaced apart lanes where film strips 218 b, 218 d are to be bondedwith lower non-woven web 215.

Lamination nip rollers 224 apply pressure to film strips 218 andnon-woven webs 213, 215 to bond film strips 218 with the respectivenon-woven webs 213, 215 and form laminate sheets 217, 219 as suggestedin FIGS. 5 and 6. In some embodiments, lamination nip rollers 224 areheated or cooled. The distance between film slitter 212 and laminator214 is minimized to minimize the distance traveled by film strips 218,which may be susceptible to tearing, before being bonded with non-wovenwebs 213, 215. Likewise, film strips 218 move in the machine directionof in-line lamination system 210 and do not experience lateral changesin direction to minimize stress on film strips 218 before laminationwith non-woven webs 213, 215. Laminate sheets 217, 219 move throughin-line lamination system 210 for roll-up or further processing at theselection of an operator.

Another embodiment of an in-line lamination system 310 in accordancewith the present disclosure is shown in FIG. 7. In-line laminationsystem 310 is similar to in-line lamination system 210 and includes afilm slitter 312 and a laminator 314. A film 316, such as a breathableor elastic plastic film, passes through slitter 312 to divide film 316into strips 318. Strips 318 pass through laminator 314 to bond withnon-woven webs 313, 315 to form separate laminate sheets 317, 319 havingalternating sections of exposed non-woven material and film laminated toand covering a portion of the underlying non-woven material.

In the illustrative embodiment, laminator 314 includes two laminationstations 342, 344 as shown in FIG. 7. Each lamination station 342, 344include adhesive applicators 322 and lamination nip rollers 324. Anon-woven material supply 326 includes supply rolls 323, 325 for feedingnon-woven webs 313, 315 into lamination stations 342, 344, respectively.Adjacent film strips 318 are directed to one of lamination stations 342,344 in an alternating pattern such that film strips 318 a, 318 c, 318 epass through lamination station 342 to bond with non-woven web 313 whilethe remaining film strips 318 b, 318 d pass through lamination station342 to bond with non-woven web 315. An idler 346 guide's film strips 318toward lamination station 344.

Adhesive applicators 322 are arranged to apply an adhesive material ontofilm strips 318 as suggested in FIG. 7. Backer rolls 348 support filmstrips 318 as the adhesive material is applied. In the illustrativeembodiment, film strips 318 a, 318 c, 318 e passing through laminationstation 342 are laterally spaced apart from one another during bondingwith upper non-woven web 313. Similarly, film strips 318 b, 318 dpassing through lamination station 344 are laterally spaced apart fromone another during bonding with lower non-woven web 315.

Lamination nip rollers 324 apply pressure to film strips 318 andnon-woven webs 313, 315 to bond film strips 318 with the respectivenon-woven webs 313, 315 and form laminate sheets 317, 319 as suggestedin FIG. 7. In some embodiments, lamination nip rollers 324 are heated orcooled. The distance between film slitter 312 and laminator 314 isminimized to minimize the distance traveled by film strips 318, whichmay be susceptible to tearing, before being bonded with non-woven webs313, 315. Likewise, film strips 318 move in the machine direction ofin-line lamination system 310 and do not experience lateral changes indirection to minimize stress on film strips 318 before lamination withnon-woven webs 313, 315. Laminate sheets 317, 319 move through in-linelamination system 310 for roll-up or further processing at the selectionof an operator.

Another embodiment of an in-line lamination system 410 in accordancewith the present disclosure is shown in FIG. 8. In-line laminationsystem 410 is similar to in-line lamination system 10 and includes afilm slitter 412 and a laminator 414. A film 416, such as a breathableor elastic plastic film, passes through slitter 412 to divide film 416into strips 418. Laminator 414 includes adhesive applicators 422 andlamination nip rollers 424 for bonding film strips 418 with non-wovenwebs 413, 415. Strips 418 pass through laminator 414 to bond with therespective non-woven webs 413, 415 to form separate laminate sheets 417,419 having alternating sections of exposed non-woven material and filmlaminated to and covering a portion of the underlying non-wovenmaterial.

Film 416 is continuously supplied to in-line lamination system 410 usingan extruder, for example. A non-woven material supply of in-linelamination system 410 is configured to continuously supply non-wovenwebs 413, 415 for lamination with film 416. Film 416 and non-woven webs413, 415 move together along a machine direction of in-line laminationsystem 410 toward laminator 414.

Another embodiment of an in-line lamination system 510 in accordancewith the present disclosure is shown in FIG. 9. In-line laminationsystem 510 is similar to in-line lamination system 10 and includes afilm slitter 512 and a laminator 514. A film 516, such as a breathableor elastic plastic film, passes through slitter 512 to divide film 516into strips 518. Strips 518 pass through laminator 514 to bond with therespective non-woven webs 513, 515 to form separate laminate sheets 517,519 having alternating sections of exposed non-woven material and filmlaminated to and covering a portion of the underlying non-wovenmaterial.

In the illustrative embodiment, laminator 514 includes alignment niprollers 524 and an ultrasonic welder 522 as shown in FIG. 10. Anon-woven material supply 526 includes supply rolls 523, 525 for feedingnon-woven webs 513, 515 into alignment nip rollers 524. Film strips 518pass through alignment nip rollers 524 such that non-woven web 513extends along an upper side of film strips 518 and non-woven web 515extends along a lower side of film strips 518.

In the illustrative embodiment, anti-bond kiss coaters 552, 554 arearranged to apply an anti-bond material, such as a deadener, alongportions of non-woven webs 513, 515 where film strips 518 are not to bebonded as suggested in FIG. 9. One embodiment of an anti-bond kisscoater 554 is illustrated in FIG. 10. Anti-bond kiss coater 554 includesa supply of anti-bond material 551, a kiss roller 553, and pass-overskids 555. Kiss roller 553 distributes the anti-bond material receivedfrom supply 551 to non-woven web 515 as non-woven web 515 passesanti-bond kiss coaters 554. Pass-over skids 555 block application of theanti-bond material along portions of non-woven web 515 where film strips518 are to be bonded. In some embodiments, pass-over skids 555 arecoated in a non-stick material, such as TEFLON. Anti-bond kiss coater552 operates similar to anti-bond kiss coater 554 for upper non-wovenweb 513 as suggested in FIG. 9.

The anti-bond material forms a barrier between film strips 518 andnon-woven webs 513, 515 to block bonding of film strips 518 along thecoated portions of non-woven webs 513, 515 during ultrasonic welding.The coated portions of non-woven web 513 are offset from the coatedportions of non-woven web 515 such that film strips 518 a, 518 c, 518 eare only bonded to non-woven web 513 and the remaining film strips 518b, 518 d are only bonded to non-woven web 515. The anti-bond materialapplied to non-woven webs 513, 515 blocks film strips 518 from bondingto both non-woven webs 513, 515 so that separate laminate sheets 517,519 can be formed.

In the illustrative embodiment, film strips 518 and non-woven webs 513,515 all pass together through ultrasonic welder 522 for bonding assuggested in FIG. 9. A support roll 556 supports film strips 518 andnon-woven webs 513, 515 during bonding. In some embodiments, supportroll 556 is machined or etched with depressions to define areas oflocalized bonding between film strips 518 and non-woven webs 513, 515 aseach passes through ultrasonic welder 522. In some embodiments, materialis added to film strips 518 or non-woven webs 513, 515 in a pattern todefine areas of localized bonding between film strips 518 and non-wovenwebs 513, 515 as each passes through ultrasonic welder 522.

Alignment nip rollers 524 collect film strips 518 and non-woven webs513, 515 and direct each toward ultrasonic welder 522 as suggested inFIG. 9. The distance between film slitter 512 and laminator 514 isminimized to minimize the distance traveled by film strips 518, whichmay be susceptible to tearing, before being bonded with non-woven webs513, 515. Likewise, film strips 518 move in the machine direction ofin-line lamination system 510 and do not experience lateral changes indirection to minimize stress on film strips 518 before lamination withnon-woven webs 513, 515. Laminate sheets 517, 519 move through in-linelamination system 510 for roll-up or further processing at the selectionof an operator.

Another embodiment of an in-line lamination system 610 in accordancewith the present disclosure is shown in FIG. 11. In-line laminationsystem 610 is similar to in-line lamination system 510 and includes afilm slitter 612 and a laminator 614. A film 616, such as a breathableor elastic plastic film, passes through slitter 612 to divide film 616into strips 618. Strips 618 pass through laminator 614 to bond with therespective non-woven webs 613, 615 to form separate laminate sheets 617,619 having alternating sections of exposed non-woven material and filmlaminated to and covering a portion of the underlying non-wovenmaterial.

In the illustrative embodiment, laminator 614 includes two laminationstations 642, 644 as shown in FIG. 11. Each lamination station 642, 644include alignment nip rollers 624 and an ultrasonic welder 622. Anon-woven material supply 626 includes supply rolls 623, 625 for feedingnon-woven webs 613, 615 into alignment nip rollers 624. Adjacent filmstrips 618 are directed to one of lamination stations 642, 644 in analternating pattern such that film strips 618 a, 618 c, 618 e passthrough lamination station 642 to bond with non-woven web 613 while theremaining film strips 618 b, 618 d pass through lamination station 642to bond with non-woven web 615. An idler 646 guide's film strips 618toward lamination station 644.

In the illustrative embodiment, film strips 618 a, 618 c, 618 e passingthrough lamination station 642 are laterally spaced apart from oneanother and pass through ultrasonic welder 622 for bonding with uppernon-woven web 613. In some embodiments, ultrasonic welder 622 is zonedto apply energy along the portions where film strips 618 and non-wovenweb 613 overlap. Likewise, film strips 618 b, 618 d passing throughlamination station 644 are laterally spaced apart from one another andpass through ultrasonic welder 622 for bonding with lower non-woven web615. In some embodiments, ultrasonic welder 622 is zoned to apply energyalong the portions where film strips 618 and non-woven web 615 overlap.

Support rolls 656 supports film strips 618 and non-woven webs 613, 615during bonding. In some embodiments, support roll 656 are machined oretched with depressions to define areas of localized bonding betweenfilm strips 618 and non-woven webs 613, 615 as each passes throughultrasonic welders 622. In some embodiments, material is added to filmstrips 618 or non-woven webs 613, 615 in a pattern to define areas oflocalized bonding between film strips 618 and non-woven webs 613, 615 aseach passes through ultrasonic welders 622.

Alignment nip rollers 624 collect film strips 618 and non-woven webs613, 615 and directs each toward ultrasonic welders 622 as suggested inFIG. 11. The distance between film slitter 612 and laminator 614 isminimized to minimize the distance traveled by film strips 618, whichmay be susceptible to tearing, before being bonded with non-woven webs613, 615. Likewise, film strips 618 move in the machine direction ofin-line lamination system 610 and do not experience lateral changes indirection to minimize stress on film strips 618 before lamination withnon-woven webs 613, 615. Laminate sheets 617, 619 move through in-linelamination system 610 for roll-up or further processing at the selectionof an operator.

In one illustrative embodiment, in-line lamination system 10 includes afilm extruder 62 for continuously forming film 16, slitter 12, andlaminator 14 as suggested in FIG. 12. Film 16 can be sent throughoptional pre-processing steps before passing through slitter 12 andlaminator 14. An optional breathable film activation station 64 isarranged to impart breathability to film 16 through perforation orring-roll activation for example. An optional elastic film activationstation 68 is arranged to impart additional elasticity to film 16. Anoptional printer 66 is arranged to print graphics or other patterns onone or both sides of film 16.

In one illustrative embodiment, laminate sheets 17, 19 formed by in-linelamination system 10 proceed to a roll-up station 72 where laminatesheets 17, 19 are collected for transportation as suggested in FIG. 13.An optional post-processing step is to slit laminate sheets 17, 19 intomultiple strips of laminate material in a slitting station 74 beforeroll-up.

In another illustrative embodiment, laminate sheets 17, 19 are formedinto a laminate product 90 (sometimes called a tri-laminate) assuggested in FIGS. 14 and 15. Film sections 36 of upper and lowerlaminate sheets 17, 19 are aligned with one another in an alignmentstation 92 and laminate sheets 17, 19 are laminated together in alamination station 94 along non-woven sections 34 forming multiplestrips of laminate product 90. In some embodiments, alignment station 92includes a sheet rotator for rotating a laminate sheet so that filmsections face each other, such as, for example, one of laminate sheets217, 219 that both have film sections facing downward and not toward oneanother as suggested in FIGS. 5 and 6. Laminate sheets 17, 19 canoptionally pass through a ring-roll activation station 91 separately orthrough a ring-roll activation station 95 after being laminated togetherto add elasticity to the non-woven material attached to film sections36. Adjacent strips of laminate product 90 are optionally separated fromone another in a slitting station 96 before roll-up for transportationin a roll-up station 98.

Laminate product 90 includes overlapping sections of film 36 surroundedby non-woven material as suggested in FIG. 15. In the illustrativeembodiment, film sections 36 form a moisture barrier and the surroundingnon-woven material 35 provides a soft exterior finish to laminateproduct 90. Laminate product 90 is useful in hygiene applications, suchas diapers and other incontinence products, and healthcare applications,such as medical gowns and drapes, for example.

Another embodiment of an in-line lamination system 710 in accordancewith the present disclosure is shown in FIG. 16. In-line laminationsystem 710 is similar to in-line lamination system 510 and includes afilm slitter 712 and a laminator 714. A film 716, such as a breathableor elastic plastic film, passes through slitter 712 to divide film 716into strips 718. Strips 718 pass through laminator 714 to bond with therespective non-woven webs 713, 715 to form separate laminate sheets 717,719 having alternating sections of exposed non-woven material and filmlaminated to and covering a portion of the underlying non-wovenmaterial.

In the illustrative embodiment, laminator 714 includes adhesiveapplicators 722 and lamination nip rollers 724 as shown in FIG. 16. Anon-woven material supply 726 includes supply rolls 723, 725 for feedingnon-woven webs 713, 715 into lamination nip rollers 724. Film strips 518pass through lamination nip rollers 724 such that non-woven web 713extends along an upper side of film strips 718 and non-woven web 715extends along a lower side of film strips 718.

Adhesive applicators 722 are arranged to apply an adhesive materialalong both sides of film strips 718 as suggested in FIG. 16. In theillustrative embodiment, anti-bond kiss coaters 752, 754 are arranged toapply an anti-bond material, such as a deadener, along portions ofnon-woven webs 713, 715 where film strips 718 are not to be bonded. Theanti-bond material forms a barrier between film strips 718 and non-wovenwebs 713, 715 to block bonding of film strips 718 along the coatedportions of non-woven webs 713, 715.

Lamination nip rollers 724 apply pressure to film strips 718 andnon-woven webs 713, 715 to bond film strips 718 with the respectivenon-woven webs 713, 715 and form laminate sheets 717, 719 as suggestedin FIG. 16. In some embodiments, lamination nip rollers 724 are heatedor cooled. The anti-bond coated portions of non-woven web 713 are offsetfrom the anti-bond coated portions of non-woven web 715 such that filmstrips 718 a, 718 c, 718 e are only bonded to non-woven web 713 and theremaining film strips 718 b, 718 d are only bonded to non-woven web 715.The anti-bond material applied to non-woven webs 713, 715 blocks filmstrips 718 from bonding to both non-woven webs 713, 715 so that separatelaminate sheets 717, 719 can be formed.

Divider rollers 728 separate laminate sheets 717, 719 as suggested inFIG. 16. Adjacent film strips 718 a, 718 b, 718 c, 718 d, 718 e divergeand are carried on non-woven webs 713, 715 as laminate sheets 717, 719separate from one another. Film strips 718 a, 718 c, 718 e form part oflaminate sheet 717 while film strips 718 b, 718 d form part of laminatesheet 719. The distance between film slitter 712 and laminator 714 isminimized to minimize the distance traveled by film strips 718, whichmay be susceptible to tearing, before being bonded with non-woven webs713, 715. Likewise, film strips 718 move in the machine direction ofin-line lamination system 710 and do not experience lateral changes indirection to minimize stress on film strips 718 before lamination withnon-woven webs 713, 715. Laminate sheets 717, 719 move through in-linelamination system 710 for roll-up or further processing at the selectionof an operator. In some embodiments, during later processing, such asduring formation of a laminate product 90 as described above, theadhesive applied to film strips 718 allows bonding of facing film strips718 as portions of laminate sheets 717, 719 are bonded together, such asby ultrasonic welding.

Another embodiment of an in-line lamination system 810 in accordancewith the present disclosure is shown in FIG. 17. In-line laminationsystem 810 is similar to in-line lamination system 710 and includes afilm slitter 812 and a laminator 814. A film 816, such as a breathableor elastic plastic film, passes through slitter 812 to divide film 816into strips 818. Strips 818 pass through laminator 814 to bond with therespective non-woven webs 813, 815 to form separate laminate sheets 817,819 having alternating sections of exposed non-woven material and filmlaminated to and covering a portion of the underlying non-wovenmaterial.

In the illustrative embodiment, laminator 814 includes adhesiveapplicators 822 and lamination nip rollers 824 as shown in FIG. 17. Anon-woven material supply 826 includes supply rolls 823, 825 for feedingnon-woven webs 813, 815 into lamination nip rollers 824. Film strips 818pass through lamination nip rollers 824 such that non-woven web 813extends along an upper side of film strips 818 and non-woven web 815extends along a lower side of film strips 818.

Adhesive applicators 822 are arranged to apply an adhesive materialalong a width of non-woven webs 813, 815 as suggested in FIG. 17. In theillustrative embodiment, zoned anti-bond print heads 852 are arranged toapply an anti-bond material, such as a deadener, along portions of film816 such that one side of each film strip 818 is coated where filmstrips 818 are not to be bonded with non-woven webs 813, 815. In someembodiments, print heads 852 are arranged after slitter 812 to apply theanti-bond material onto film strips 818. In some embodiments, printheads 852 are ink jet print heads, and the anti-bond material is in theform of an ink solution capable of passing through the ink jet printheads. The anti-bond material forms a barrier between film strips 818and non-woven webs 813, 815 to block bonding of film strips 818 alongthe coated portions.

Lamination nip rollers 824 apply pressure to film strips 818 andnon-woven webs 813, 815 to bond film strips 818 with the respectivenon-woven webs 813, 815 and form laminate sheets 817, 819 as suggestedin FIG. 17. Film strips 818 block bonding together of non-woven webs813, 815 as film strips 818 and non-woven webs 813, 815 pass throughlamination nip rollers 824. In some embodiments, lamination nip rollers824 are heated or cooled. The anti-bond coated portions of adjacent filmstrips 818 are offset such that film strips 818 a, 818 c, 818 e are onlybonded to non-woven web 813 and the remaining film strips 818 b, 818 dare only bonded to non-woven web 815. The anti-bond material applied tofilm strips 818 blocks film strips 818 from bonding to both non-wovenwebs 813, 815 so that separate laminate sheets 817, 819 can be formed.

Divider rollers 828 separate laminate sheets 817, 819 as suggested inFIG. 17. Adjacent film strips 818 a, 818 b, 818 c, 818 d, 818 e divergeand are carried on non-woven webs 813, 815 as laminate sheets 817, 819separate from one another. Film strips 818 a, 818 c, 818 e form part oflaminate sheet 817 while film strips 818 b, 818 d form part of laminatesheet 819. The distance between film slitter 812 and laminator 814 isminimized to minimize the distance traveled by film strips 818, whichmay be susceptible to tearing, before being bonded with non-woven webs813, 815. Likewise, film strips 818 move in the machine direction ofin-line lamination system 810 and do not experience lateral changes indirection to minimize stress on film strips 818 before lamination withnon-woven webs 813, 815. Laminate sheets 817, 819 move through in-linelamination system 810 for roll-up or further processing at the selectionof an operator. In some embodiments, during later processing, such asduring formation of a laminate product 90 as described above, theadhesive applied to non-woven webs 813, 815 allows bonding of portionsof laminate sheets 817, 819, such as by passing through a set oflamination nip rollers, while facing film strips 818 are left un-bonded.

In illustrative embodiments, an extruded film is slit prior tolamination with a non-woven web and waste is minimized by sendingalternating strips of film to an upper lamination station and a lowerlamination station where either full width continuous non-woven webs arefed in, or multiple webs of non-woven are fed in, to minimize trimmingof the non-woven webs during processing. Sending alternating lanes totwo lamination stations allows for the gaps between strips duringlamination while retaining the full area of the extruded film as goodproduct. The system produces laminate sheets in-line, simultaneously andproduces them without complex handling of narrow film strips.

In illustrative embodiments, the laminate sheets are produced usingadhesive or ultrasonic bonding where the film is extruded, quenched,oriented, optionally printed, and then laminated to a non-woven web. Thelaminate sheets are then wound into rolls. The laminate sheets areseparated into strips of laminate material where the film strip is about50 percent of the width of the non-woven web. A full width of the systemis used to produce the laminate sheets maximizing output.

1. An in-line lamination system comprising a film slitter aligned alonga machine direction and adapted to receive a sheet of film along themachine direction and form film strips from the sheet of film, the filmstrips aligned along the machine direction in a series of adjacentlanes, a material supply adapted to provide a first substantiallycontinuous web and a second substantially continuous web along themachine direction, and a laminator aligned with the film slitter alongthe machine direction and configured to receive the film strips, firstweb, and second web and bond selectively the film strips in adjacentlanes alternatingly to one of the first web or second web to form afirst laminate sheet and a second laminate sheet, each of the firstlaminate sheet and a second laminate sheet having alternating sectionsof exposed material and film material.
 2. The in-line lamination systemof claim 1, wherein the laminator includes adhesive applicators and apair of lamination nip rollers.
 3. The in-line lamination system ofclaim 2, wherein the adhesive applicators are configured to apply anadhesive material to the first web and second web and the lamination niprollers are configured to force the film strips against the first weband second web.
 4. The in-line lamination system of claim 3, furthercomprising print heads configured to apply an anti-bond material to thefilm strips.
 5. The in-line lamination system of claim 2, wherein theadhesive applicators are configured to apply an adhesive material to thefilm strips and the lamination nip rollers are configured to force thefilm strips against the first web and second web.
 6. The in-linelamination system of claim 5, further comprising anti-bond kiss coatersconfigured to apply an anti-bond material to the first web and secondweb in zones.
 7. The in-line lamination system of claim 1, wherein thelaminator includes a pair of alignment nip rollers and an ultrasonicwelder.
 8. The in-line lamination system of claim 7, further comprisinganti-bond kiss coaters configured to apply an anti-bond material to thefirst web and second web in zones.
 9. The in-line lamination system ofclaim 1, wherein the laminator includes a first lamination station and asecond lamination station, each lamination station is arranged along thecommon direction and off-set from one another, the first laminationstation is configured to receive a first plurality of the film stripsand the first web, the second lamination station is configured toreceive a second plurality of the film strips and the second web, andthe first plurality of film strips and the second plurality of filmstrips each include film strips in non-adjacent lanes.
 10. The in-linelamination system of claim 1, further comprising a film supply adaptedto provide the sheet of film in a continuous form.
 11. The in-linelamination system of claim 10, wherein the film supply is an extruder.12. The in-line lamination system of claim 10, further comprising abreathable film activation station configured to impart breathability tothe film.
 13. The in-line lamination system of claim 10, furthercomprising an elastic film activation station configured to impartelasticity to the film.
 14. The in-line lamination system of claim 1,further comprising a slitting station configured to separate the firstlaminate sheet and the second laminate sheet into strips of laminatematerial.
 15. The in-line lamination system of claim 1, furthercomprising an alignment station configured to align film strips of thefirst laminate sheet with film strips of the second laminate sheet inconfronting relation to one another.
 16. The in-line lamination systemof claim 15, further comprising a lamination station configured to bondthe first laminate sheet to the second laminate sheet along the sectionsof exposed material to form a laminate product.
 17. The in-linelamination system of claim 16, further comprising a slitting stationconfigured to separate the laminate product into strips of laminateproduct.
 18. An in-line lamination system comprising a film slitteraligned along a machine direction and adapted to receive a sheet of filmalong the machine direction and form film strips from the sheet of film,the film strips aligned along the machine direction in a series ofadjacent lanes, a material supply adapted to provide a firstsubstantially continuous web and a second substantially continuous webalong the machine direction, and a laminator aligned with the filmslitter along the machine direction and configured to receive the filmstrips, first web, and second web, wherein the laminator is configuredto provide means for selectively bonding the film strips in adjacentlanes alternatingly to one of the first web or second web to form afirst laminate sheet and a separate second laminate sheet, each of thefirst laminate sheet and a second laminate sheet having alternatingsections of exposed material and film material.
 19. The in-linelamination system of claim 18, wherein the laminator includes a firstlamination station and a second lamination station, each laminationstation is arranged along the common direction and off-set from oneanother, the first lamination station is configured to receive a firstplurality of the film strips and the first web, the second laminationstation is configured to receive a second plurality of the film stripsand the second web, and the first plurality of film strips and thesecond plurality of film strips each include film strips in non-adjacentlanes.
 20. The in-line lamination system of claim 10, further comprisingat least one of a breathable film formation station configured to formthe sheet of film into a breathable film and an elastic film formationstation configured to form the sheet of film into an elastic film.